Bicycle shoe sole

ABSTRACT

A bicycle shoe has an upper portion with a sole attached to the upper portion. The sole has upper and lower outer surfaces that define a toe section, an arch section, a ball section and a heel section with a longitudinal axis extending between the toe and heel sections. The ball section has a cleat attachment area surrounding at least one cleat attachment hole extending between the upper and lower outer surfaces. At least the arch section is configured with a transverse cross section having a center sole area with a first predetermined height, a medial side sole area with a second predetermined height and a lateral outside sole area with a third predetermined height, the first predetermined height being smaller than said second and third predetermined heights. Preferably, the sole upper and lower inner surfaces defining an interior cavity.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention generally relates to a bicycle shoe. Morespecifically, the present invention relates to a sole of a bicycle shoe.

[0003] 2. Background Information

[0004] Bicycling is becoming an increasingly more popular form ofrecreation as well as a means of transportation. Moreover, bicycling hasbecome a very popular competitive sport for both amateurs andprofessionals. Whether the bicycle is used for recreation,transportation or competition, the bicycle industry is constantlyimproving the various components of the bicycle as well as the frame ofthe bicycle. One component that has been extensively redesigned is thebicycle shoe.

[0005] Conventionally, cycling shoe soles are formed, for example, of aresin or the like mixed with glass fiber chips for reinforcement. Withthe above construction, the sole is subjected to a strong bending forceapplied longitudinally of the shoe at a pedaling time. Therefore, thesole is formed solid to withstand the bending force. This is because animproved strength can hardly be expected of the sole having the glassfiber chips arranged in random orientation without fiber layers.Consequently, the sole itself is heavy, and the cyclist must ride abicycle by pedaling hard with heavy soles, which has the disadvantage ofexhausting the cyclist.

[0006] Moreover, weight has been reduced in shoe soles using amanufacturing method, in which a lightweight core material is surroundedby multiple fibrous layers and the core material and the fibrous layersare integrated using a resin material. For example, U.S. Pat. No.5,406,723 to Okajima illustrates a shoe sole produced in this manner.However, this layered shoe sole is still heavier than desired. There isa need for a very lightweight shoe sole for a shoe that is sufficientlydurable to withstand a strong bending force applied longitudinally ofthe shoe.

[0007] In view of the above, it will be apparent to those skilled in theart from this disclosure that there exists a need for an improvedbicycle shoe sole. This invention addresses this need in the art as wellas other needs, which will become apparent to those skilled in the artfrom this disclosure.

SUMMARY OF THE INVENTION

[0008] One object of the present invention is to provide a bicycle shoesole that is lightweight.

[0009] Another object of the present invention is to provide a bicycleshoe sole, which is very light weight and yet has a sufficientdurability against a strong bending force acting longitudinally of theshoe.

[0010] Another object of the present invention is to provide a bicycleshoe sole that is relatively simple to manufacture.

[0011] The foregoing objects can basically be attained by providing abicycle shoe sole that comprises upper and lower outer surfaces, andupper and lower inner surfaces defining an interior cavity. The upperand lower outer surfaces define a toe section, an arch section, a ballsection and a heel section with a longitudinal axis extending betweenthe toe and heel sections. The interior cavity includes a transversecross section having a center sole area with a first predeterminedheight, a medial side sole area with a second predetermined height and alateral outside sole area with a third predetermined height. The firstpredetermined height is smaller than the second and third predeterminedheights. The ball section has a cleat attachment area surrounding atleast one cleat attachment hole extending between the upper and lowerouter surfaces.

[0012] The foregoing objects can further be attained by providing abicycle shoe sole that basically comprises upper and lower outersurfaces defining a toe section, an arch section, a ball section and aheel section with a longitudinal axis extending between the toe and heelsections. At least the arch section is configured with a transversecross section having a center sole area with a first predeterminedheight, a medial side sole area with a second predetermined height and alateral outside sole area with a third predetermined height. The firstpredetermined height is smaller than the second and third predeterminedheights. The ball section has a cleat attachment area surrounding atleast one cleat attachment hole extending between the upper and lowerouter surfaces.

[0013] These and other objects, features, aspects and advantages of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which, taken in conjunction with theannexed drawings, discloses a preferred embodiment of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Referring now to the attached drawings which form a part of thisoriginal disclosure:

[0015]FIG. 1 is a side elevational view of a bicycle shoe with a bicycleshoe sole in accordance with a first embodiment of the presentinvention;

[0016]FIG. 2 is an exploded perspective view of a cleat assembly, thebicycle shoe sole illustrated in FIG. 1 in accordance with the firstembodiment of the present invention and an inner sole;

[0017]FIG. 3 is a top plan view of the bicycle shoe sole illustrated inFIGS. 1 and 2 in accordance with the first embodiment of the presentinvention;

[0018]FIG. 4 is a bottom plan view of the bicycle shoe sole illustratedin FIGS. 1-3 in accordance with the first embodiment of the presentinvention;

[0019]FIG. 5 is a first transverse cross-sectional view of the bicycleshoe sole illustrated in FIGS. 1-4 as viewed along section line 5-5 ofFIG. 3;

[0020]FIG. 6 is a second transverse cross-sectional view of the bicycleshoe sole illustrated in FIGS. 1-4 as viewed along section line 6-6 ofFIG. 3;

[0021]FIG. 7 is a third transverse cross-sectional view of the bicycleshoe sole illustrated in FIGS. 1-4 as viewed along section line 7-7 ofFIG. 3;

[0022]FIG. 8 is a fourth transverse cross-sectional view of the bicycleshoe sole illustrated in FIGS. 1-4 as viewed along section line 8-8 ofFIG. 3;

[0023]FIG. 9 is a fifth transverse cross-sectional view of the bicycleshoe sole illustrated in FIGS. 1-4 as viewed along section line 9-9 ofFIG. 3;

[0024]FIG. 10 is a sixth transverse cross-sectional view of the bicycleshoe sole illustrated in FIGS. 1-4 as viewed along section line 10-10 ofFIG. 3;

[0025]FIG. 11 is a seventh transverse cross-sectional view of thebicycle shoe sole illustrated in FIGS. 1-4 as viewed along section line11-11 of FIG. 3;

[0026]FIG. 12 is an eighth transverse cross-sectional view of thebicycle shoe sole illustrated in FIGS. 1-4 as viewed along section line12-12 of FIG. 3;

[0027]FIG. 13 is a ninth longitudinal cross-sectional view of thebicycle shoe sole illustrated in FIGS. 1-4 as viewed along section line13-13 of FIG. 3;

[0028]FIG. 14 is a tenth longitudinal cross-sectional view of thebicycle shoe sole illustrated in FIGS. 1-4 as viewed along section line14-14 of FIG. 3;

[0029]FIG. 15 is a top plan view of a core material that forms part ofthe structure of the bicycle shoe sole in accordance with the firstembodiment of the present invention;

[0030]FIG. 16 is a partial diagrammatic transverse cross-sectional viewof a partially formed portion of the bicycle shoe sole of FIGS. 1-4 toillustrate the fiber layers that form the ball section at a time priorto molding, in which the dimensions are exaggerated to show the fiberlayers;

[0031]FIG. 17 is a partial diagrammatic transverse cross-sectional viewof a partially formed portion of the bicycle shoe sole of FIGS. 1-4 toillustrate the fiber layers that form a portion of the arch section at atime prior to molding, in which the dimensions are exaggerated to showthe fiber layers; and

[0032]FIG. 18 is a partial diagrammatic longitudinal cross-sectionalview of a partially formed portion of the bicycle shoe sole of FIGS. 1-4to illustrate how the number of fiber layers in the bicycle shoe sole ofFIGS. 1-17 varies between toe, ball, arch and heel sections of thebicycle shoe sole, in which the dimensions are exaggerated to show thefiber layers.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Selected embodiments of the present invention will now beexplained with reference to the drawings. It will be apparent to thoseskilled in the art from this disclosure that the following descriptionsof the embodiments of the present invention are provided forillustration only and not for the purpose of limiting the invention asdefined by the appended claims and their equivalents.

[0034] Referring initially to FIGS. 1 and 2, a bicycle shoe 10 isillustrated with a bicycle shoe sole 12 in accordance with a firstembodiment of the present invention. The bicycle shoe 10 has a cleat 14attached thereto by a plurality of fasteners 16, a plurality of washers18 and a mounting plate 20 with a plurality of holes 22 that receive thefasteners 16. Only one fastener 16 and one washer 18 are shown for easeof illustration. The number of washers 18 and fasteners 16 can be variedas needed and/or desired. The cleat 14 is designed to be used withclipless or step-in pedal (not shown). The precise construction of thecleat 14 will not be discussed or illustrated in detail herein, sincethe basic construction of the cleat 14 is old and well known in theprior art. Moreover, it should be apparent to those skilled in the artfrom this disclosure that the present invention should not be limited tothe precise construction of the non-claimed portions of the bicycle shoe10 and the cleat 14 as discussed and illustrated herein. For example,various types of cleats can be used with the bicycle shoe 10 of thepresent invention with slight modifications to the bicycle shoe 10.

[0035] The bicycle shoe 10 illustrated in FIG. 1 is a left bicycle shoe.Of course, the right bicycle shoe would be substantially identical tothe left bicycle shoe illustrated in FIG. 1, but substantially a mirrorimage thereof. Therefore, the bicycle shoe 10 as used herein refers toeither a left bicycle shoe or a right bicycle shoe, and the drawings anddescription used herein will not differentiate therebetween.

[0036] Basically, the bicycle shoe 10 has a shoe upper portion 24 andthe bicycle shoe sole 12. The bicycle shoe sole 12 includes an outershoe sole 26 and an inner shoe sole or cushion 28, as shown in FIG. 2.The outer shoe sole 26 is fixedly attached to the shoe upper portion 24in a conventional manner. The inner shoe sole 28 is located within thebicycle shoe 10 and overlies the outer shoe sole 26. The inner shoe sole28 can be constructed of one or more separate flexible layers (e.g., twolayers 28 a and 28 b as shown in FIG. 2). The precise construction ofthe shoe upper portion 24, and the inner shoe sole 28 will not bediscussed or illustrated in detail herein, since the basic constructionof a bicycle shoe is old and well-known in the prior art. Moreover, itshould be apparent to those skilled in the art from this disclosure thatthe present invention should not be limited to the precise constructionof the non-claimed portion of bicycle shoe 10 as discussed andillustrated herein.

[0037] The outer shoe sole 26 is a hard, rigid member that is relativelyinflexible. Preferably, the outer shoe sole 26 is constructed of aplurality of overlapping carbon fiber layers bound together by a resinmaterial. Alternatively, the outer shoe sole 26 is constructed of aplurality of carbon fiber layers and a plurality of glass fiber layersarranged in an overlapping fashion with the carbon fiber layers and theglass fiber layers being bound together by a resin material. The resinmaterial can be previously impregnated into the carbon fiber layersand/or glass fiber layers. Alternatively, the outer shoe sole 26 can beconstructed of a plurality of carbon fiber layers and/or glass layersthat are not previously impregnated with a resin material, and a resinmaterial can be added to bind these carbon fiber layers and/or glassfiber layers together.

[0038] Referring now to FIGS. 3-14, the outer shoe sole 26 isillustrated in more detail. Basically, the outer shoe sole 26 has anupper outer surface 36, a lower outer surface 38, an upper inner surface40 and a lower inner surface 42. The upper and lower inner surfaces 40and 42 define an interior cavity 44. As shown in FIGS. 3, 4 and 13, theupper and lower outer surfaces 36 and 38 define a toe section 46, a ballsection 48, an arch section 50 and a heel section 52 with a longitudinalaxis A extending between the toe and heel sections 46 and 52.Preferably, as explained below, the ball section 48 is formed of fifteenlayers of the carbon fiber layers and/or the glass fiber layers. The toesection 46, the arch section 50 and the heel section 52, on the otherhand, are preferably formed of ten layers of the carbon fiber layersand/or the glass fiber layers, with the portions of the toe section 46and the arch section 50 that are adjacent to the ball section 48 beingformed to gradually transition from fifteen layers down to ten layers.The toe section 46 preferably has at least one hole 64 therethrough thatextends between the upper and lower outer surfaces 36 and 38. Asexplained below in more detail, the at least one hole 64 can be drilledthrough the outer shoe sole 26 after the outer shoe sole 26 is molded.

[0039] As seen in FIGS. 3 and 13, the ball section 48 has a cleatattachment area 54 surrounding a plurality of cleat attachment holes 56that extend between the upper and lower outer surfaces 36 and 38. Arecess portion 58 in the upper outer surface 36 of the outer shoe sole26 defines the cleat attachment area 54. This recess portion 58 ispreferably V-shaped and does not include the interior cavity 44. Rather,the layers of material and the resin forming the cleat attachment area54 are stacked together between the upper and lower outer surfaces 36and 38 such that the interior cavity 44 does not extend into the cleatattachment area 54.

[0040] The interior cavity 44 has a length that extends between the heeland toe sections 52 and 46. Preferably, the interior cavity 44 is acontinuous cavity having a single large section that extends through theheel and arch sections 52 and 50, two smaller narrow sections thatextend through the ball section 48 and into the toe section 46. In otherwords, the interior cavity 44 extends as a single section through theheel and arch sections 52 and 50, and diverges into at least twosections that extend through the ball section 48 and into the toesection 46. The interior cavity 44 preferably has a transverse crosssection that varies along the longitudinal axis A between the heel andtoe sections 52 and 46. Certain transverse cross section areas of theouter shoe sole 26 have a W-shape formed along the lower outer surface38. This W-shape is at least partially formed by a recess 59 in thelower outer surface 38, as shown in FIG. 4.

[0041] Referring now to FIG. 5, a transverse cross sectional view of theouter shoe sole 26 is shown along section line 5-5 of FIG. 3. In otherwords, FIG. 5 shows a cross section in the heel section 52. The upperand lower inner surfaces 40 and 42 define the interior cavity 44. Thetransverse cross section of the interior cavity 44 has a center solearea 44 a, a medial side sole area 44 b and a lateral outside area 44 c.The center sole area 44 a has a first minimum predetermined height H₁.The medial side sole area 44 b has a second maximum predetermined heightH₂. The lateral outside sole area 44 c has a third maximum predeterminedheight H₃. The predetermined heights H₁, H₂ and H₃ of the interiorcavity 44 are measured between the upper and lower inner surfaces 40 and42. Although the predetermined heights H₁, H₂ and H₃ vary in acontinuous manner along the longitudinal direction throughout the heelsection 52, the height H₁ is always less than H₂ and also always lessthan H₃ as seen in FIG. 5. Moreover, FIG. 5 shows that the lower innerand lower outer surfaces 42 and 38 define a generally W-shapedtransverse cross section therebetween. The upper outer and upper innersurfaces 36 and 40 define a slightly bowed U-shaped transverse crosssection therebetween.

[0042] Referring now to FIGS. 6, 7 and 8, transverse cross sectionalviews of the arch section 50 of the outer shoe sole 26 are shown alongsection lines 6-6, 7-7 and 88 of FIG. 3, respectively. As seen in eachof these figures, the upper inner surface 40 of the arch section 50 ofthe outer shoe sole 26 includes a pair longitudinally extending ribs 40a and 40 b that are laterally spaced apart. The longitudinally extendingribs 40 a and 40 b preferably extend at least along entire the archsection 50. More preferably, the longitudinally extending ribs 40 a and40 b extend along the ball section 48 to the heel section 52. Thus, theinterior cavity 44 has, at least in the arch section 50, a transversecross section with a center sole area 44 a, a medial side sole area 44 band a lateral outside sole area 44 c. The center sole area 44 a has afirst minimum predetermined height H₁. The medial side sole area 44 bhas a second maximum predetermined height H₂. The lateral outside solearea 44 c has a third maximum predetermined height H₃. The predeterminedheights H₁, H₂ and H₃ are measured between the upper and lower innersurfaces 40 and 42. As seen in FIGS. 6, 7 and 8, the predeterminedheights H₁, H₂ and H₃ vary in a continuous manner along the longitudinaldirection through the arch section 50. However, the predetermined heightH₁ is always less than the predetermined heights H₂ and H₃. Thelongitudinally extending ribs 40 a and 40 b are preferably formed by aplurality of carbon fiber layers that are stacked to form the desiredshape of the longitudinally extending ribs 40 a and 40 b. The verticalthickness of the longitudinally extending ribs 40 a and 40 b can vary asneeded and/or desired. Each of the FIGS. 6, 7 and 8 shows that the lowerinner and lower outer surfaces 42 and 38 define a generally W-shapedtransverse cross section therebetween.

[0043] Moreover, the upper outer and upper inner surfaces 36 and 40define a slightly bowed U-shaped transverse cross section therebetween.FIGS. 6-8 also show that the rib 40 a has a maximum vertical thicknessmeasured between the upper outer surface 36 and the upper inner surface40 that is greater than the first minimum predetermined height H₁. Therib 40 b has a maximum vertical thickness measured between the upperouter surface 36 and the upper inner surface 40 that is greater than thefirst minimum predetermined height H₁. FIG. 7 shows the transverse crosssection along line 7-7 of FIG. 3, which is located in the arch section50. The rib 40 a has a maximum vertical thickness measured between theupper outer surface 36 and the upper inner surface 40 that is less thanthe second maximum predetermined height H₂. The maximum verticalthickness of the rib 40 b is less than the third maximum predeterminedheight H₃.

[0044] Referring now to FIGS. 9 and 10, transverse cross-sectional viewsof the ball section 48 of the outer shoe sole 26 are shown along sectionlines 9-9 and 10-10 of FIG. 3, respectively. As described above, theball section 48 includes the recess portion 58 that defines the cleatattachment area 54. As seen in FIGS. 9 and 10, a portion of the outershoe sole 26 where the cleat attachment area 54 is formed does notinclude the cavity 44. Accordingly, in the ball section 48, the interiorcavity 44 is diverged into two smaller sections such that the cleatattachment area 54 is located between these two smaller sections of thecavity 44, as seen in FIGS. 9 and 10.

[0045] Referring now to FIGS. 11 and 12, transverse cross-sectionalviews of the toe section 46 of the outer shoe sole 26 are shown alongsection lines 11-11 and 12-12 of FIG. 3, respectively. As seen in FIGS.11 and 12, the interior cavity 44 preferably extends continuouslythrough the transverse direction of the outer shoe sole 26.

[0046] Referring now to FIGS. 13 and 14, longitudinal cross-sectionalviews of the outer shoe sole 26 are shown along section lines 13-13 and14-14 of FIG. 3, respectively. As seen in FIG. 13, the interior cavity44 longitudinally extends from the heel section 52 to the toe section 46except under the cleat attachment area 54. Moreover, as seen in FIG. 14,the at least one hole 64 is formed so that the at least one hole 64extends between the upper and lower outer surfaces 36 and 38 in the toesection 46.

[0047] Referring now to FIG. 15, a core material 60 is shown. In theillustrated embodiment of the invention, the interior cavity 44 of theouter shoe sole 26 has a lightweight core material 60 therein.Basically, the core material 60 includes a first opening 126, a secondopening 128 and a pair of receiving recesses 130. The core material isused in combination with layers of carbon fibers and/or glass fibers, asmentioned above, to form the outer shoe sole 26. The first opening 126is arranged such that fiber layers above and below the first opening 126can be molded together in the area of the first opening 126. This moldedarea defines the cleat attachment area 54. The cleat attachment area 54is free of the core material 60. The core material 60 can be, forexample, polyurethane foam. However, the core material is not limited toa foam material. For example, a high specific gravity material can beused instead of polyurethane foam. Preferably, the core material 60 isbasically used to form the interior cavity 44 during the production ofthe outer shoe sole 26. Moreover, the interior cavity 44 of the outershoe sole 26 can be constructed in such a manner that the interiorcavity 44 is empty, i.e., the interior cavity 44 is an air space. Forexample, the outer shoe sole 26 can be formed using an air tube suchthat the interior cavity 44 of the outer shoe sole 26 is empty.

[0048] The core material 60 is preferably preformed prior to the outershoe sole 26 is molded so that the core material 60 has a generallyW-shaped transverse cross section. Of course, it will be apparent tothose skilled in the art from this disclosure that the core material 60can be arranged to have a flat cross section. In any event, the corematerial 60 deforms in accordance with the shape of the upper and lowerinner surfaces 40 and 42 in the molding process of the outer shoe sole26.

[0049]FIGS. 16, 17 and 18 show diagrammatic transverse cross sectionalviews of the outer shoe sole 26 before the outer shoe sole 26 is molded.As seen in FIG. 16, each receiving recess 130 of the core material 60 isarranged and configured to receive one of the ribs 40 a or 40 b. Each ofthe ribs 40 a and 40 b are formed by molding a stack of carbon fibersheets and/or glass fiber sheets, as shown in FIGS. 16 and 17. In themolding process of the outer shoe sole 26, the receiving recesses 130are deformed in a great extent so as to fit with the shape of the ribs40 a or 40 b. Of course, it will be apparent to those skilled in the artfrom this disclosure that the receiving recesses 130 can be omitted inorder to achieve the same effect of the present invention. In otherwords, even though the core material 60 does not include the receivingrecesses 130, the core material will deform so as to fit with the shapeof the ribs 40 a or 40 b.

[0050] As seen in FIGS. 16, 17 and 18, the interior cavity 44 dividesthe outer shoe sole 26 into an upper layered portion 61 and a lowerlayered portion 62. The upper outer surface 36 and the upper innersurface 40 define the upper layered portion 61. The lower outer surface38 and the lower inner surface 42, on the other hand, define the lowerlayered portion 62. In the illustrated embodiment, the upper layeredportion 61 includes layers 61 a-61 e (five layers), while the lowerlayered portion 62 includes layers 62 a-62 j (ten layers). In onepreferred embodiment, all of the layers 61 a-61 e and 62 a-62 j areconstructed of carbon fiber layers bound together by a resin material.Thus, the upper outer surface 36 is part of the upper layered portion 61that includes at least one carbon fiber layer located adjacent the upperouter surface 36. The upper inner surface 40 is part of the upperlayered portion 61 that includes at least one carbon fiber layer locatedadjacent the upper inner surface 40. Likewise, the lower outer surface38 is part of the lower layered portion 62 that includes at least onecarbon fiber layer located adjacent the lower outer surface 38. Thelower inner surface 42 is part of the lower layered portion thatincludes at least one carbon fiber layer located adjacent the lowerinner surface 42.

[0051] In another preferred embodiment, some of the layers 61 a-61 e and62 a-62 j are constructed of carbon fiber layers and some of the layers61 a-61 e and 62 a-62 j are constructed of glass fiber layers. Whilevarious combinations of carbon fiber layers and glass fiber layers arepossible, it is preferably to have the layers closest to the upper andlower outer surfaces 36 and 38 constructed of carbon fiber layers andthe layers closest to the upper and lower inner surfaces 40 and 42constructed of glass fiber layers. For example, the layers 61 d, 61 e,62 i and 62 j are constructed of carbon fiber layers and the layers 61a-61 c and 62 a-62 h are constructed of glass fiber layers.

[0052] Referring now to FIG. 18, the ball section 48 is preferablyformed of all fifteen layers 61 a-61 e and 62 a-62 j. The toe section46, the arch section 50 and the heel section 52, on the other hand, arepreferably formed of ten layers 61 a-61 e and 62 a-62 e, with theportions of the toe section 46 and the arch section 50 that are adjacentto the ball section 48 being partially formed of the layers 62 f-62 j togradually transition from the ball section 48 to the toe section 46 andthe arch section 50.

[0053] Now, one method of manufacturing the outer shoe sole 26 of thepresent invention will be discussed. First, the core material 60 isproduced to form the desired shape of the interior cavity 44. In theillustrated embodiment, the core material 60 is a foam material that hasthe two receiving recesses 130, which correspond to the shape of thelongitudinally extending ribs 40 a and 40 b. The core material 60 alsohas the first and second holes 126 and 128, which correspond to thecleat attachment area 54 and an opening in the outer shoe sole 26,respectively.

[0054] Next, the portion of the outer shoe sole 26 that overlies thecore material 60 is formed. This preferred method uses a plurality offiber layers or sheets that are formed of either all carbon fiber layersor sheets, or a combination of carbon fiber layers or sheets and glassfiber layers or sheets. A thermosetting resin such as phenol resin isused for impregnating these fiber layers or sheets. Preferably, thesefiber layers are previously impregnating with the resin. Alsopreferably, when carbon fibers are used in the previously impregnatedfiber layers, reinforcing carbon fibers extending in one direction areused in the fiber layers.

[0055] First, the carbon fiber layers forming the longitudinallyextending ribs 40 a and 40 b (e.g., carbon fiber layers as shown in FIG.17) are stacked and placed in the receiving recesses 130 of the corematerial 60 to form the desired shape of the longitudinally extendingribs 40 a and 40 b. The vertical thickness of the longitudinallyextending ribs 40 a and 40 b can vary as needed and/or desired dependingon the lengths and number of the carbon fiber layers used to make thelongitudinally extending ribs 40 a and 40 b. Of course, one or more ofthe fiber layers used to make the longitudinally extending ribs 40 a and40 b can be a glass fiber layer or sheet. In fact, all of the fiberlayers used to make the longitudinally extending ribs 40 a and 40 b canbe a glass fiber layer.

[0056] Then, the fiber layers 61 a-61 e and 62 a-62 j, which are thepreviously impregnated fiber layers 61 a-61 e and 62 a-62 j, are appliedto upper and lower surfaces of the core material 60 to form the upperlayered portion 61 and the lower layered portion 62 with the interiorcavity 44 being filled with the core material 60. The fiber layers orsheets 61 a-61 e and 62 a-62 j are formed of either all carbon fiberlayers or sheets, or a combination of carbon fiber layers or sheets andglass fiber layers or sheets. A thermosetting resin such as phenol resinis used for impregnating these fiber layers or sheets. Preferably, thesefiber layers 61 a-61 e and 62 a-62 j are previously impregnating withthe resin. Also preferably, when carbon fibers are used in thepreviously impregnated fiber layers 61 a-61 e and 62 a-62 j, reinforcingcarbon fibers extending in one direction are used in the fiber layers 61a-61 e and 62 a-62 j. In these prior steps, the fiber layers 61 a-61 eare stacked successively upwardly from the core material 60 toconstitute the upper layered portion 61 of the outer shoe sole 26. Thefiber layers 62 a-62 j are arranged successively downwardly from thelower surface of the core material 60 to constitute the lower layeredportion 62 of the outer shoe sole 26.

[0057] The outer shoe sole 26 having the various fiber layers overlyingthe core material 60 is placed in dies and shaped by pressurization andheating. Consequently, the outer shoe sole 26 is completed when theimpregnated resin of the previously impregnated fiber layers forming theribs 42 a and 42 b, the fiber layers 61 a-61 e and 62 a-62 j becomehardened by the heat. When phenol resin is used as the impregnatedresin, the heating temperature is 140° C. and the pressing time about 2hours, for example. The pressure is applied to a degree to preventexpansion of the core material 60. At this time, secondary foaming ofthe polyurethane resin of the core material 60 is prevented. The fibersheets can have, for example, a thickness of about 0.3 mm to about 0.35mm before heating and a thickness of about 0.2 mm after heating. Thebase resin of the fiber sheets can be, for example, an epoxy resin. Thedies are shaped such that the outer shoe sole 26 will have a shapeillustrated in FIGS. 3-14 after the pressurization and heating. Ofcourse it will be apparent to those skilled in the art from thisdisclosure that the transverse and/or longitudinal cross sections of theouter shoe sole 26 after the pressurization and heating will not beidentical to the cross sections shown in FIGS. 5-14. In other words, thefiber layers and the core material 60 will be deformed in unpredictablemanner in the course of pressurization and heating. In any event, itwill be apparent to those skilled in the art from this disclosure thatthe outer shoe sole 26 will achieve the same effects as the presentinvention as long as it has generally similar cross sectional shapes asthe cross sections shown in FIGS. 5-14.

[0058] Now, the cleat attachment holes 56 that extend between the upperand lower outer surfaces 36 and 38 are formed by drilling.

[0059] In the illustrated embodiment, a thermosetting phenol resin wasused with previously impregnated fiber layers. It is also possible touse a thermoplastic resin or other resins that harden with the lapse oftime. The term “resin” includes both synthetic and natural resins.

[0060] As used herein, the following directional terms “forward,rearward, above, downward, vertical, horizontal, below and transverse”as well as any other similar directional terms refer to those directionsof a shoe that is configures in accordance with the present invention.Accordingly, these terms, as utilized to describe the present inventionshould be interpreted relative to a shoe equipped with a shoe sole inaccordance with the present invention.

[0061] The terms of degree such as “substantially”, “about” and“approximately” as used herein mean a reasonable amount of deviation ofthe modified term such that the end result is not significantly changed.These terms should be construed as including a deviation of ±5% of themodified term if this would not negate the meaning of the word itmodifies.

[0062] While only selected embodiments have been chosen to illustratethe present invention, it will be apparent to those skilled in the artfrom this disclosure that various changes and modifications can be madeherein without departing from the scope of the invention as defined inthe appended claims. Furthermore, the foregoing descriptions of theembodiments according to the present invention are provided forillustration only, and not for the purpose of limiting the invention asdefined by the appended claims and their equivalents.

What is claimed is:
 1. A bicycle shoe sole comprising: upper and lowerouter surfaces defining a toe section, an arch section, a ball sectionand a heel section with a longitudinal axis extending between said toeand heel sections, and upper and lower inner surfaces defining aninterior cavity with a transverse cross section having a center solearea with a first predetermined height, a medial side sole area with asecond predetermined height and a lateral outside sole area with a thirdpredetermined height, said first predetermined height being smaller thansaid second and third predetermined heights, said ball section having acleat attachment area surrounding at least one cleat attachment holeextending between said upper and lower outer surfaces.
 2. The bicycleshoe sole according to claim 1, wherein said interior cavity is filledwith a core material.
 3. The bicycle shoe sole according to claim 1,wherein said upper outer surface of said shoe sole is part of an upperlayered portion that includes at least one carbon fiber layer locatedadjacent said upper outer surface, and said lower outer surface of saidshoe sole is part of a lower layered portion that includes at least onecarbon fiber layer located adjacent said lower outer surface.
 4. Thebicycle shoe sole according to claim 3, wherein said upper inner surfaceof said shoe sole is part of said upper layered portion that includes atleast one carbon fiber layer located adjacent said upper inner surface,and said lower inner surface of said shoe sole is part of said lowerlayered portion that includes at least one carbon fiber layer locatedadjacent said lower inner surface.
 5. The bicycle shoe sole according toclaim 3, wherein said upper inner surface of said shoe sole is part ofsaid upper layered portion that includes at least one glass fiber layerlocated adjacent said upper inner surface, and said lower inner surfaceof said shoe sole is part of said lower layered portion that includes atleast one glass fiber layer located adjacent said lower inner surface.6. The bicycle shoe sole according to claim 1, wherein said upper innersurface of said shoe sole is part of an upper layered portion thatincludes at least one carbon fiber layer located adjacent said upperinner surface, and said lower inner surface of said shoe sole is part ofa lower layered portion that includes at least one carbon fiber layerlocated adjacent said lower inner surface.
 7. The bicycle shoe soleaccording to claim 1, wherein said upper inner surface of said shoe soleis part of an upper layered portion that includes at least one glassfiber layer located adjacent said upper inner surface, and said lowerinner surface of said shoe sole is part of a lower layered portion thatincludes at least one glass fiber layer located adjacent said lowerinner surface.
 8. The bicycle shoe sole according to claim 1, whereinsaid cleat attachment area defines a recess portion in said upper outersurface of said shoe sole.
 9. The bicycle shoe sole according to claim1, wherein said upper inner surface of said shoe sole includes a pairlongitudinally extending ribs that are laterally spaced apart.
 10. Abicycle shoe sole comprising: upper and lower outer surfaces defining atoe section, an arch section, a ball section and a heel section with alongitudinal axis extending between said toe and heel sections; andupper and lower inner surfaces defining an interior cavity with atransverse cross section, at least said arch section being configuredwith a transverse cross section having a center sole area with a firstpredetermined height, a medial side sole area with a secondpredetermined height and a lateral outside sole area with a thirdpredetermined height, said first predetermined height being smaller thansaid second and third predetermined heights, said ball section having acleat attachment area surrounding at least one cleat attachment holeextending between said upper and lower outer surfaces.
 11. The bicycleshoe sole according to claim 10, further comprising upper and lowerinner surfaces defining an interior cavity.
 12. The bicycle shoe soleaccording to claim 11, wherein said interior cavity is filled with acore material.
 13. The bicycle shoe sole according to claim 10, whereinsaid upper outer surface of said shoe sole is part of an upper layeredportion that includes at least one carbon fiber layer located adjacentsaid upper outer surface, and said lower outer surface of said shoe soleis part of a lower layered portion that includes at least one carbonfiber layer located adjacent said lower outer surface.
 14. The bicycleshoe sole according to claim 13, further comprising upper and lowerinner surfaces defining an interior cavity, said upper inner surface ofsaid shoe sole is part of said upper layered portion that includes atleast one carbon fiber layer located adjacent said upper inner surface,and said lower inner surface of said shoe sole is part of said lowerlayered portion that includes at least one carbon fiber layer locatedadjacent said lower inner surface. 15 The bicycle shoe sole according toclaim 13, further comprising upper and lower inner surfaces defining aninterior cavity, said upper inner surface of said shoe sole is part ofsaid upper layered portion that includes at least one glass fiber layerlocated adjacent said upper inner surface, and said lower inner surfaceof said shoe sole is part of said lower layered portion that includes atleast one glass fiber layer located adjacent said lower inner surface.16. The bicycle shoe sole according to claim 11, wherein said upperinner surface of said shoe sole is part of an upper layered portion thatincludes at least one carbon fiber layer located adjacent said upperinner surface, and said lower inner surface of said shoe sole is part ofa lower layered portion that includes at least one carbon fiber layerlocated adjacent said lower inner surface.
 17. The bicycle shoe soleaccording to claim 11, wherein said upper inner surface of said shoesole is part of an upper layered portion that includes at least oneglass fiber layer located adjacent said upper inner surface, and saidlower inner surface of said shoe sole is part of a lower layered portionthat includes at least one glass fiber layer located adjacent said lowerinner surface.
 18. The bicycle shoe sole according to claim 10, whereinsaid cleat attachment area defines a recess portion in said upper outersurface of said shoe sole.
 19. The bicycle shoe sole according to claim11, wherein said upper inner surface of said shoe sole includes a pairlongitudinally extending ribs that are laterally spaced apart.
 20. Abicycle shoe sole comprising: upper and lower outer surfaces defining atoe section, an arch section, a ball section and a heel section with alongitudinal axis extending between said toe and heel sections, upperand lower inner surfaces defining an interior cavity with a transversecross section, at least of one said upper and lower outer surfaces beingconfigured to define a longitudinal extending recess, said ball sectionhaving a cleat attachment area surrounding at least one cleat attachmenthole extending between said upper and lower outer surfaces.